Automotive e-ssentials

Non-destructive dynamic component testing for homologation purposes

At the beginning of November 2016, operations were officially launched at the DYCOT laboratory in Bezděčín. As with all TÜV SÜD Czech laboratories, tests are performed here either for the purpose of developing of vehicles and vehicle parts (verification tests, e.g. checking the conformity of production series), or for homologation (approval) tests.

In addition to the technical equipment of the laboratory, which was described in the last edition of the TÜV SÜD Automotive E-ssentials, an important instrument for any laboratory is to be covered by various authorisations and accreditations. These determine the markets on which the test reports can be used, and the approvals issued on the basis of these reports. During October and November, the DYCOT laboratory was verified by auditors from VSCC of Taiwan and the Czech Institute of Accreditation. As a result of these assessments, the credentials of TÜV SÜD Czech were extended to include Taiwan. Furthermore, the laboratory is accredited according to ISO/IEC 17025:2005 standard for performing tests at the DYCOT facility and at the Bezděčín laboratory in general. Accreditation from the Czech Institute of Accreditation together with additional credentials of TÜV SÜD Czech gives rise to the possibility of conducting homologation tests in the DYCOT laboratory, on the basis of which manufacturers are issued a homologation under the ECE/UN regulations or EU legislation.

In the following we provide further details regarding the main homologation or approval tests which can be carried out in the DYCOT laboratory on vehicles and their systems and components.

Tests on strength of seat anchorages according to ECE Regulation 17.

The tests are carried out on the whole vehicle body of a passenger vehicle fitted with seats. First, a pulse is applied to the vehicle body in forward and then in rearward direction. Afterwards a penetration test is carried out with regard to the vehicle itself and the luggage placed in the luggage area. A similar test is described in Regulation ECE 126 (strength of the partitioning systems separating luggage areas).

Tests on anchorage strength and energy absorption of bus seats according to ECE Regulation 80.

This regulation allows both static and dynamic tests; the dynamic ones are carried out on a rig simulating a bus floor with several seats, and with test dummies placed on the seats. More manufacturers have recently started choosing this more expensive dynamic test, because it often results in simpler and cheaper seat designs.

Dynamic tests on door latches and retainers according to ECE Regulation 11.

The tests are carried out in a total of 5 directions – on the whole vehicle body with all doors and then on part of the vehicle body fitted only with rear (fifth) doors. The rear door must not open even with a relatively strong pulse.

Dynamic tests on children’s seats according to ECE Regulations44 and129.

This type of test is carried out very often in type-approval, product qualification and conformity of production verifications of child restraint systems. The movement and acceleration of child dummies is measured in the seat during a simulated frontal impact. During 2017, preparations are being made to extend the facilities at DYCOT to include an advanced system for simulating side impacts (ALIS). Thanks to this, we will be able to carry out in the laboratory complex side-impact tests on child seats in accordance with ECE Regulation 129, and these require the latest generation of child dummies, which we already have.

Dynamic tests on child seat anchorages in accordance with Australian rule ADR 34/2.

This rule is a combination of the ECE 17 and ECE 44 test procedures and it represents a very demanding test which sufficiently verifies in particular the strength of the back seats, including anchorages placed here for child seats.

Dynamic determination of the head impact zone in accordance with ECE Regulation 21.

Where it can be shown through a large number of sled tests that the vehicle interior does not come into contact with the heads of passengers in the vehicle during an impact, then no such requirements are used for the interior part of the vehicle. This test is therefore carried out on a vehicle body fitted with seats containing test dummies and several directions of movement are selected for the vehicle Body.

The aim is to verify the strength of roof luggage carriers, often used as “racks” for carrying skis, including the resistance of their anchorages on the vehicle roof. These tests are then used for national approval of roof carriers not only in the Czech Republic but also in other countries.

The ECE regulations have parallels in the VSTD regulations for Taiwan; all are part of the aforementioned authorisation of TÜV SÜD Czech from VSCC. In addition to this, some countries have a self-certification system, and therefore no special authorisation is required for conducting the tests. These countries include, for example, the US, Canada, South Korea and countries of the Persian Gulf. All of these territories have their own regulations which are similar to the ECE regulations, and tests in the DYCOT laboratory may, of course, be used for demonstrating conformity with the local regulations.

Focusing on the European area, the output of the homologation tests according to the ECE regulations is a test report, which can be used for various authorities to issue homologations. In the Czech Republic, the authority is the Ministry of Transport and the homologations with the E8 mark are the most frequent products of homologation tests in the DYCOT laboratory. If the customer is interested, however, homologation can also be carried out by other authorities where TÜV SÜD Czech is accredited, for example KBA (Germany, E1), RDW (the Netherlands, E4), VCA (Great Britain, E11) and others.

The equipment at the DYCOT laboratory makes it possible to carry out homologation tests quickly and efficiently while ensuring exact compliance with the test pulse. The supervision of an expert and the rapid provision of homologation are – together with the test – the overall homologation package of services, which TÜV SÜD Czech can provide to the customers.